HKS BOV nightmare

[hawaii3]

i was installing my HKS BOV from cp-e yesterday and the bottom bolt broke off. now i have to drill out the hole and re-tread it. any suggestions on how to go about this? oh and how do you take off the intercooler? is it just taking the 3 bolts off and the boost tubes?

[dparm1984]

Get a tap and dye set. This is why you need to be really careful with aluminum and use a torque wrench.

[shadrag]

oh and how do you take off the intercooler? is it just taking the 3 bolts off and the boost tubes?

Yep

[SPEED3TYPE2]

man that sucks .. did you tighten the bolt to hard??

[Rotus8]

It's weird, it looks like the other tapped hole already has been stripped and had an insert put in it. You got elves working on your car?

After you pull the intercooler off the engine, you can remove the pipe from the cooler with 4 bolts. Much easier to work on without danger of dinging up the fins on the cooler.

[SPEED3TYPE2]

man what a bummer your all excited about your new bov and then that happens and you can't drive your car..

[hawaii3]

man that sucks .. did you tighten the bolt to hard??

yup. lol

thanks for the help guys

[dparm1984]

Go buy a torque wrench so this doesn't happen again. Don't even ask what is involved with re-tapping the block itself...

[onikaze]

if you have only damaged or broken off the head of a bolt and feel the threads should be intact i recommend the following methods.

go to your local hardware store and buy a lefthand drill bit that is about 2/3s the size of the bolt you want to remove and/or an automatic punch with a fine point tip. (i would get both to save a trip)

first find a high spot on the broken bolt using the automatic punch put a dimple on the back side of the high spot in order to try to rotate the broken bolt counter clockwise. once you have a decent dimple hold the automatic punch at about 35-45 degrees in order to use the force of the automatic punch to rotate the broken off bolt. it will take patients and technique but if this works you will not have to retap the hole (so long as the thread are not damaged).

if the aformentioned method does not work for you or sounds like too much work you can use the lefthand drill bit method. use a pin punch to make a dimple in the very center of your work surface (the top of the broken bolt) this will help you stay centered as much as possible so that you are less likely to damage the treads. in most cases a lefthand drill bit, a lil luck, low speed/high torque set drill and light touch on the trigger will do the job very nicely.

these are 2 generally low cost way to remove broken bolt. i have used both of these methods for a number of years and have had much success. i hope this helps you.

[MS3077]

if you have only damaged or broken off the head of a bolt and feel the threads should be intact i recommend the following methods.

go to your local hardware store and buy a lefthand drill bit that is about 2/3s the size of the bolt you want to remove and/or an automatic punch with a fine point tip. (i would get both to save a trip)

first find a high spot on the broken bolt using the automatic punch put a dimple on the back side of the high spot in order to try to rotate the broken bolt counter clockwise. once you have a decent dimple hold the automatic punch at about 35-45 degrees in order to use the force of the automatic punch to rotate the broken off bolt. it will take patients and technique but if this works you will not have to retap the hole (so long as the thread are not damaged).

if the aformentioned method does not work for you or sounds like too much work you can use the lefthand drill bit method. use a pin punch to make a dimple in the very center of your work surface (the top of the broken bolt) this will help you stay centered as much as possible so that you are less likely to damage the treads. in most cases a lefthand drill bit, a lil luck, low speed/high torque set drill and light touch on the trigger will do the job very nicely.

these are 2 generally low cost way to remove broken bolt. i have used both of these methods for a number of years and have had much success. i hope this helps you.

I've got the same problem but mine envolves one of the bolts that attach to the intercooler cover. Thanks for the info!

[voiceKoil]

if you have only damaged or broken off the head of a bolt and feel the threads should be intact i recommend the following methods.

go to your local hardware store and buy a lefthand drill bit that is about 2/3s the size of the bolt you want to remove and/or an automatic punch with a fine point tip. (i would get both to save a trip)

first find a high spot on the broken bolt using the automatic punch put a dimple on the back side of the high spot in order to try to rotate the broken bolt counter clockwise. once you have a decent dimple hold the automatic punch at about 35-45 degrees in order to use the force of the automatic punch to rotate the broken off bolt. it will take patients and technique but if this works you will not have to retap the hole (so long as the thread are not damaged).

if the aformentioned method does not work for you or sounds like too much work you can use the lefthand drill bit method. use a pin punch to make a dimple in the very center of your work surface (the top of the broken bolt) this will help you stay centered as much as possible so that you are less likely to damage the treads. in most cases a lefthand drill bit, a lil luck, low speed/high torque set drill and light touch on the trigger will do the job very nicely.

these are 2 generally low cost way to remove broken bolt. i have used both of these methods for a number of years and have had much success. i hope this helps you.

+1

I like the drilling technic with an easy out, shoukld work fine. Ive never tried the automatic punch, Hope I wont have to ;)

[voiceKoil]

It's weird, it looks like the other tapped hole already has been stripped and had an insert put in it. You got elves working on your car?

After you pull the intercooler off the engine, you can remove the pipe from the cooler with 4 bolts. Much easier to work on without danger of dinging up the fins on the cooler.

Yeh what the hell is that?? I dont think mines like that (rofl)(boom04)

[aaronc7]

is any of the threads sticking out? I did the same thing and was able to twist it out with something like this

http://img.diynetwork.com/DIY/2004/01/22/dtsc101_channellock01_e.jpg